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Important note
NOTE: Timing belt check and replacement intervals are subject to change at any time. To ensure that you are using the
most up-to-date and accurate information available connect to Autodata Online. Contact your distributor about connecting
to Autodata Online.

Important Note

All service items are vital to the smooth running and reliability of a vehicle, none more so than the timing belt and its associated
components. For this reason we have highlighted important information from the manufacturers' service schedules covering the
intervals for checks and replacements. Be sure that you make the vehicle owner aware of this information. Industry best practice is
to ensure that the vehicle owner is made aware of the importance of replacing the timing belt and its associated components
according to the manufacturers' specification. The service history and the use of the vehicle must be considered when deciding the
correct course of action. If there is any doubt to the serviceability of the belt and its components, they should be replaced.

Timing belt replacement intervals

Where possible the recommended intervals have been compiled from vehicle manufacturers' information. In a few instances no
recommendation has been made by the manufacturer and the decision to replace the belt must be made from the evidence of a
thorough examination of the condition of the existing belt.
Apart from the visible condition of the belt, which is explained fully in the General Instructions/Toothed Timing Belts section, there are
several other factors which must be considered when checking a timing belt:

1. Is the belt an original or a replacement?

2. When was the belt last replaced and was it at the correct mileage?
3. Is the service history of the vehicle known?
4. Has the vehicle been operated under arduous conditions which might warrant a shorter replacement interval?
5. Is the general condition of other components in the camshaft drive, such as the tensioner, pulleys, and other ancillary components
driven by the timing belt, typically the water pump, sound enough to ensure that the life of the replacement belt will not be affected?
6. If the condition of the existing belt appears good, can you be satisfied that the belt will not fail before the next check or service is due?
7. If the belt does fail, have you considered the consequences? If the engine is an INTERFERENCE type then considerable expensive
damage may well be the result.
8. The cost of replacing a belt as part of a routine service could be as little as 5 to 10% of the repair cost following a belt failure. Make
sure your customer is aware of the consequences.
9. If in doubt about the condition of the belt - RENEW it.
10. Refer to the Toothed Timing Belts/Service Replacement section for further information relating to arduous or adverse operating
conditions, inspection and service replacement.

Manufacturer: Volkswagen Model: Golf/Golf Estate (91-98) 1,9D TDI © Autodata Limited 2010
Engine code: ALE Output: 66 (90) 4000 Valid forever. 1/11/2022
Tuned for: Year: 1997-98 V8.500-
 Replacement Interval Guide

Replacement Interval Guide

Volkswagen recommend:

Engine code AAZ:

Check & adjust or replacement if necessary every 20,000 miles.
No manufacturer's recommended replacement interval.

Engine code 1Z/AFN/AHU/ALE/AVG:

Check condition and width every 10,000 miles or 12 months, whichever occurs first.
Replacement every 60,000 miles (tensioner pulley must also be replaced).

NOTE: Volkswagen UK recommend the timing belt is replaced every 4 years if the replacement mileage is not reached.
The previous use and service history of the vehicle must always be taken into account.

Check For Engine Damage

Check For Engine Damage

CAUTION:This engine has been identified as an INTERFERENCE engine in which the possibility of valve-to-piston damage
in the event of a timing belt failure is MOST LIKELY to occur. A compression check of all cylinders should be performed
before removing the cylinder head.

Repair Times - hrs

Repair Times - hrs

Without Cat

Remove and install 1,90

With Cat

Remove and install 1,90

Special Tools

Special Tools

Injection pump sprocket locking pin - VAG No.2064.

Camshaft setting bar - VAG No.2065A.
Two-pin wrench - Matra V.159.

Special Precautions

Special Precautions

Manufacturer: Volkswagen Model: Golf/Golf Estate (91-98) 1,9D TDI © Autodata Limited 2010
Engine code: ALE Output: 66 (90) 4000 Valid forever. 1/11/2022
Tuned for: Year: 1997-98 V8.500-
 Disconnect battery earth lead.
DO NOT turn crankshaft or camshaft when timing belt removed.
Remove glow plugs to ease turning engine.
Turn engine in normal direction of rotation (unless otherwise stated).
DO NOT turn engine via camshaft or other sprockets.
Observe all tightening torques.
Check diesel injection pump timing after belt replacement.

Removal

Removal

1. Remove:
Auxiliary drive belts.
Auxiliary drive belt tensioner pulley (if fitted).
Timing belt upper cover [1] .
Cylinder head cover.

2. Turn crankshaft to TDC on No.1 cylinder. Ensure flywheel timing marks aligned [2] .
3. Fit setting bar No.2065A to rear of camshaft [3] . Centralise camshaft using feeler gauges.
4. Lock injection pump sprocket [4] . Use tool No.2064.
5. Remove:
Crankshaft pulley bolts [5] .
Crankshaft pulley [6] .
Timing belt lower cover [7] .

6. Slacken tensioner nut [8] . Turn tensioner anti-clockwise away from belt. Lightly tighten nut.
7. Except AAZ: Remove guide pulley [9] .
8. Remove timing belt.
NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Installation

Installation

IMPORTANT: DO NOT reuse old belt if width is less than 22 mm.

1. Ensure flywheel timing marks aligned [2] .

2. Ensure camshaft setting bar fitted correctly [3] .
3. Ensure locking pin located correctly in injection pump sprocket [4] .
4. Slacken camshaft sprocket bolt 1/2 turn [10] .
5. Loosen sprocket from taper using a drift through hole in timing belt rear cover. Sprocket should turn freely without tilting.
6. Fit timing belt in anti-clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets.
7. Except AAZ: Fit guide pulley. Tighten bolt to 25 Nm [9] .
8. Remove locking pin from injection pump sprocket [4] .
9. Slacken tensioner nut [8] .
10. Turn automatic tensioner pulley clockwise until notch and raised mark on tensioner aligned [11] . Use wrench Matra V.159 [12] .
11.
Manufacturer: Volkswagen Model: Golf/Golf Estate (91-98) 1,9D TDI © Autodata Limited 2010
Engine code: ALE Output: 66 (90) 4000 Valid forever. 1/11/2022
Tuned for: Year: 1997-98 V8.500-
 11. Tighten tensioner nut to 20 Nm [8] .
12. Ensure flywheel timing marks aligned [2] . Tighten camshaft sprocket bolt to 45 Nm [10] .
13. Remove camshaft setting bar [3] .
14. Turn crankshaft two turns clockwise until timing marks aligned [2] .
15. Ensure camshaft setting bar can be fitted [3] .
16. Ensure locking pin can be inserted in injection pump sprocket [4] .
17. Apply firm thumb pressure to belt. Tensioner marks should move out of alignment [11] .
18. Release thumb pressure from belt. Tensioner marks should realign. If not: Repeat tensioning procedure.
19. Install:
Timing belt lower cover [7] .
Crankshaft pulley [6] .

20. Tighten crankshaft pulley bolts to 25 Nm [5] .

21. Install components in reverse order of removal.

Manufacturer: Volkswagen Model: Golf/Golf Estate (91-98) 1,9D TDI © Autodata Limited 2010
Engine code: ALE Output: 66 (90) 4000 Valid forever. 1/11/2022
Tuned for: Year: 1997-98 V8.500-
Manufacturer: Volkswagen Model: Golf/Golf Estate (91-98) 1,9D TDI © Autodata Limited 2010
Engine code: ALE Output: 66 (90) 4000 Valid forever. 1/11/2022
Tuned for: Year: 1997-98 V8.500-